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Rapid manufacturing of porous metal prostheses

a technology of porous metal and prosthesis, which is applied in the field of porous metal prosthesis manufacturing, can solve the problems of high temperature, a significant amount of time, and the need for orthopaedic prosthesis manufacturing to be completed

Active Publication Date: 2013-01-17
ZIMMER INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present patent is about an orthopaedic prosthesis that has a solid bearing layer, a porous bone-ingrowth layer, and an interdigitating layer between them. The patent also describes a method for rapidly manufacturing this prosthesis using a laser sintering process. The technical effects of this design include better bone growth, reduced inflammation, and improved stability of the implant. The method of manufacturing involves depositing metal powder particles and then using a laser to form solid metal that interdigitates with the porous structure of the prosthesis. This results in a more secure and reliable connection between the solid metal component and the porous metal component of the prosthesis.

Problems solved by technology

Diffusion bonding, however, requires a significant amount of time to complete and subjects the orthopaedic prosthesis to high temperatures.

Method used

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  • Rapid manufacturing of porous metal prostheses
  • Rapid manufacturing of porous metal prostheses
  • Rapid manufacturing of porous metal prostheses

Examples

Experimental program
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Embodiment Construction

[0023]FIG. 1 provides an exemplary method 100 for designing and manufacturing an orthopaedic prosthesis. Method 100 is exemplified with reference to FIGS. 2-7.

[0024]Beginning at step 102 of method 100 (FIG. 1), a porous substrate 200 is provided having a large plurality of struts or ligaments 202 that define open spaces or pores 204 therebetween, as shown in FIG. 2. Ligaments 202 may be constructed, at least in part, of a first biocompatible metal, such as tantalum, a tantalum alloy, niobium, a niobium alloy, or another suitable metal, for example. In an exemplary porous substrate 200, pores 204 between ligaments 202 form a matrix of continuous channels having no dead ends, such that growth of cancellous bone and / or soft tissue through porous substrate 200 is uninhibited. Thus, porous substrate 200 may provide a matrix into which cancellous bone and / or soft tissue may grow to provide fixation of porous substrate 200 to the patient's bone.

[0025]According to an exemplary embodiment of...

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Abstract

An orthopaedic prosthesis and a method for rapidly manufacturing the same are provided. The orthopaedic prosthesis includes a solid bearing layer, a porous bone-ingrowth layer, and an interdigitating layer therebetween. A laser sintering technique is performed to manufacture the orthopaedic prosthesis.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application claims priority from U.S. Provisional Patent Application Ser. No. 61 / 507,151, filed Jul. 13, 2011, the disclosure of which is hereby expressly incorporated by reference herein in its entirety.FIELD OF THE DISCLOSURE[0002]The present disclosure relates to porous metal prostheses. More particularly, the present disclosure relates to rapid manufacturing of porous metal prostheses.BACKGROUND OF THE DISCLOSURE[0003]Orthopaedic prostheses are commonly used to replace at least a portion of a patient's bone following traumatic injury or deterioration due to aging, illness, or disease, for example.[0004]When the orthopaedic prosthesis is implanted into a joint, the orthopaedic prosthesis may be configured to articulate with an adjacent orthopaedic component. For example, when the orthopaedic prosthesis is implanted into the patient's hip joint, the orthopaedic prosthesis may be socket-shaped to receive and articulate with an adjace...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): A61F2/28B05D3/06
CPCA61L27/04B22F3/11A61L27/56B33Y80/00Y02P10/25B22F3/105A61F2/28B05D1/12B05D3/0254B05D5/00
Inventor LI, JIAGRINER, ADAM M.
Owner ZIMMER INC
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